Bulkforum; May 12th 2009 - Bergen.

Integrated Operations - Parallels between Oil & Gas and Shipping

Recent developments in Oil & Gas industry

collaborative decision making in Operation and
Maintenance

Predicting the way forward in Ship Operation and

Maintenance

Harald Sleire

MARINTEK
Department of Maintenance Technology
Trondheim, Norway
MARINTEK 1
 Outline
 Condition-based maintenance – why?

 Oil & Gas industry challenges and constraints

 Integrated Operations / E-Field / Smart-Field
- a convenient, high-profile enabler for improved maintenance
 Center for Integrated Operations in the Petroleum Industry
- a research initiative in Norway (CRI*)
 Condition monitoring on static equipment
- Separators, Heat exchangers, Safety critical valves, Chokes
 Summary; Oil & Gas

 Shipping industry challenges and constraints

 Shipping; Collaboration & Remote support - TOCC
 Data communication, Technical Condition Indexing
 Summary; Shipping
CRI – Centre for Research-based Innovation

MARINTEK 2
Oil & Gas facilities
Challenges & constraints:
•Physical isolation
•Communication
•Weather / seasons
•Reliable condition monitoring data
•Data analysis and trending capability
•Maintenance not optimised
•Optimising production and overall recovery
•Maximising production availability
•Monitoring and KPI’s for continual improvement
•Up-turn in business
•Shortage of experienced competent staff
•Age profile of staff
•HSE
•Corporate image
•Profit
MARINTEK 4
Oil & Gas; Operation & Maintenance
As is (and may become worse)

MARINTEK 5
Maintenance

Too little of the right Too much of the Continue with the
maintenance right maintenance same amount of the
wrong maintenance

Safety/integrity Integrity Safety/integrity

Availability Availability Availability

Maintenance Optimization
Critically assess Maintenance

Condition based maintenance

MARINTEK 7
Why increase Condition-based Maintenance in oil
and gas industry?
 Unnecessary maintenance leads to decreased regularity and
increased maintenance costs
 Lack of knowledge about the technical condition of the
components can make the maintenance period longer than planned
 ~50% of personnel injuries offshore occur in connection with
maintenance (Petroleum Safety Authority Norway)
 To increase the knowledge about the failure mechanisms and
prediction of remaining lifetime
 Early Fault Detection systems are dependent on reliable sensor data
from condition monitoring
 Other onshore industries have good experience with condition based
maintenance

MARINTEK 8
Integrated Operations / E-field / Smart-field
- a convenient high-profile enabler for improved maintenance

…covers much more than just ”operations”

To facilitate:
- communication of information
- between people and organisations (geographically spread)
- shared situational awareness
in order to achieve better, faster decisions.

It involves:
Man (People), Technology & Organisation (MTO)

Applicable to:
Oil and Gas, Medicine, Shipping, and much more …….

MARINTEK 9
 Centre for Integrated Operations in the
Petroleum Industry www.ntnu.no/iocenter

Conducts research, innovation and education

within the IO field, to promote accelerated
production, increased oil recovery,
reduced operating costs and enhanced NTNU
safety and environmental standards. SINTEF
IFE
PROGRAM 1
Drilling and well construction

PROGRAM 2:
Reservoir management and production optimization

PROGRAM 3:
Operation and maintenance Oil Suppliers
PROGRAM 4: Companies
Integration across disciplines

CRI – Centre for Research-based Innovation

MARINTEK 10
RESEARCH CHALLENGES FOR INTEGRATED OPERATIONS

Visualization

Smarter Geographically
Data processing dispersed teams
decisions

Wearable
computing
Sensor technology
and automation
MARINTEK 11
Condition Monitoring on Static Equipment

The situation today:

 The technical condition of static equipment is not monitored in the
same way as for pumps and compressors
 Much information from the monitoring systems is not used
 The reliability of instrumentation & signals is questionable
 Time-based (RBI) insp & maintenance during shutdowns

Equipment types which warrant focus:

 Separators
 Heat exchangers
 Safety critical valves and chokes

MARINTEK 12
 Failure detection methods on static
“Oil & Gas” equipment offshore

Detection Method % contribution to detection of

failure
Casual observation/ unknown 60-65 %

Periodic preventive maintenance 10-15%

Continuous condition monitoring 10-15%

Inspection 5%

Other (production interference, on 5-10%

demand, functional testing etc.)

MARINTEK 13
Safety Critical Valves; test rig

MARINTEK 14
Separators; phase I laboratory set-up
Luft tilførsel 7 bar

til data logger

separator
P
1 atm.

til data logger

0-40m3/time max. 40m3 og 2 bar (4kW)

MARINTEK 15
 Oil & Gas facilities: Operation & Maintenance

Overcoming some challenges & constraints:

•Physical isolation
•Communication
•Weather / seasons
•Reliable condition monitoring data Production / Maint team

•Data analysis and trending capability

•Maintenance not optimised
•Optimising production and overall recovery
Subsurface team: reservoir
•Maximising production availability
•Monitoring and KPI’s for continual improvement
•Up-turn in business
•Shortage of experienced competent staff
Vendor: rotating machines
•Age profile of staff
•HSE
•Corporate image

MARINTEK 16
 Summary – Oil & Gas
 Failure detection should be dominated by continuous or periodic condition
monitoring, and not casual observations by personnel
 Required Technology is available (and used on exception basis), but often still
not specified in Philosophies / Tenders as required by company
 Man and Organisation aspects are at least as challenging as Technology
 Condition-based predictive maintenance must be promoted to decrease the
number & frequency of shutdowns and increase the efficiency and lifetime of
the equipment
 Data sharing & and remote decision support will lead to
 Increased safety & integrity
 Increased life time of the equipment
 Increased process regularity
 decreased maintenance costs

 The costs due to periodic shutdown and/or decreased efficiency should be

emphasised and highlighted

MARINTEK 17
Shipping: Operation & Maintenance
Challenges & constraints:
•Physical isolation
•Communication
•Weather / seasons
•Reliable condition monitoring data
•Data analysis and trending capability
•Maintenance not optimised
•Optimise operational efficiency & fuel
•Maximise time at sea / Minimise off-hire
•Monitoring and KPI’s for continuous improvement
•Fluctuation in business
•Shortage of experienced competent staff
•Age profile of staff
•Health, Safety & Environmental impact
•Corporate image
•Profit
MARINTEK 19
An example of “collaboration” in shipping

Improve competence and tools for utilisation of technical

operational data in the maritime industry

MARINTEK 20
Data communication:

Fibre optic cable? Oil & Gas; real-time data in real time

Satellite communication? Automatic data transmission as required

Satellite communication? Periodic e-mail with .xml data files

MARINTEK 21
TOCC project
Main engine performance
SHIP
Auxiliary engine performance

Feedback Hull and propeller performance

Infrastructure

Registration Support

User meetings
OFFICE
Management

MARINTEK 22
Indexing fleet performance
Technical performance
Fleet Mgr.
Superintendent

Alarm

Alert

OK
Ship

MARINTEK 23
TOCC procedure
Implementing Performance Measurement in the organisation

•Receive xml/email
•Install forms •Validate data
•Develop forms •Input measure data •Store data •Receives report
•Input ship static data •Form validate data •Analyze data •Maintenance
•Send forms to ship •Data sent to TOCC •Generate report
•Send report to ship
•Send report to office

MARINTEK 24
Keys to success

Selection and maintenance of instrumentation

Procedures for performance measurement

Quality control of practise versus procedures

Feedback and corrective actions to users/reporters

Follow-up of deviations – responsibility and support

MARINTEK 25
TOCC examples

 Improvement at fleet level

 Improvement at detail level where corrective action can be
recognised

MARINTEK 26
Fleet with less than 10 vessels

MARINTEK 27
Fleet with approx. 20 vessels

MARINTEK 28
 Ideal value

MARINTEK 29
 Ideal value

MARINTEK 30
 Summary – Shipping
 Many of the Shipping challenges are similar to those in Oil & Gas
 The justification is apparent for a trend towards:
 Remote monitoring, shared awareness, decision support, KPI’s
 Shipping is more standardised than offshore, and may benefit more from operations support
centre
 Failure detection should be dominated by continuous or periodic condition monitoring,
and not casual observations by personnel
 Required Technology is available (and used on exception basis), but often still not
specified in Philosophies / Tenders as required by company
 Man and Organisation aspects are at least as challenging as Technology
 Condition-based predictive maintenance must be promoted to decrease the number &
frequency of shutdowns and increase the efficiency and lifetime of the equipment
 Data sharing & and remote decision support will lead to
 Increased safety & integrity
 Increased life time of the equipment
 Increased process regularity (Maximise time at sea / Minimise off-hire)
 decreased maintenance costs
 The costs due to periodic shutdown and/or decreased efficiency should be emphasised
and highlighted
MARINTEK 31